Was it Perot who used to always say the Devil is in the details? Well on page 16 XL drawings it shows how to build you Joy Stick. If you look in the upper left hand corner it shows the aileron arm assembly. Besides the arm itself it shows 1, 1" length of 1 1/8" .035 welded to 3/8" bushing welded directly to it. Now take look at the center sketch where it shows the stick/aluminum rod assembly mounted to tabs welded to station 2 &3. Well it all looks just hunkey dory, but in truth you have created a pinch point on top of the tab on station 3 and the bottom and sides of the 1" aluminum tube. If you do your sub assemblies like the sketches you will find you will have to do a lot of filing to the top of the tab welded on station 3. The pulley assembly on station two the 1" aluminum tube does not cross over the top of the tab so there is no conflict there. I would suggest that when you weld your bushings to the sleeves you space them at least 1/16" apart before welding. This way you will have some clearance, and you won't remove so much material from the top and sides of your rear tab.
Gil
